CFD–Experimental Analysis of Combustion and Energy Performance in an IDR Metallurgical Furnace Fueled with a Residual Oil–Solvent Blend

This study presents a combined computational fluid dynamics (CFD) and experimental evaluation of an adjustable direct-injection reciprocating (IDR) metallurgical furnace fueled by a multicomponent residual oil–solvent mixture. An axisymmetric CFD model, incorporating k–ω SST turbulence modeling, Eddy Dissipation Concept (EDC) combustion, and Discrete Ordinates radiation, was validated against infrared thermography and Process Analytical Technology (PAT) measurements obtained under actual operational conditions. The residual mixture operated in a turbulence-controlled regime (Da < 1), reaching maximum internal temperatures of 1199 °C and achieving a thermal efficiency of 84.6% (based on LHV). Numerical predictions agreed with thermographic data to within 5% across the stabilized operational window. Under comparable process parameters, the alternative fuel reduced cycle time and operational costs compared with diesel and natural gas whilst maintaining stable combustion. Methodological clarifications encompass a consolidated, dimensionally consistent set of equations, a QoI-based mesh-independence study, and a concise summary of the experimental configuration to enhance reproducibility.